Otto Group Enables AI-driven Intelligent Robot Coordination With the Digital Twin Developed by Roboverse Reply

Reply is supporting the global retailer Otto Group in implementing a central, AI-driven virtual control system for intelligent robotic orchestration. Developed as part of a strategic collaboration between Otto Group, Reply, and NVIDIA, the “Robotic Coordination Layer” enables the training, simulation, and orchestration of autonomous mobile robots and stationary systems, accelerating delivery times and enhancing service levels

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At the centre is a high-fidelity digital twin, serving as a precise replica of the warehouse environment and accurately representing the positions, movements, and interactions of all robotic systems. Developed thanks to Roboverse Reply’s expertise in robotic integration and 3D computing, this digital twin provides a unified, data-driven foundation that enables continuous optimisation and detailed process analysis.

The “Robotic Coordination Layer”, developed by tech and consulting provider Otto Group one.o, builds on the digital twin by connecting it to essential systems such as robot fleet management solutions and the warehouse management system (WMS). Through this integration, the system not only visualises, coordinates, and manages all robotic fleets from a central platform, but also allows virtual reconfiguration of warehouse areas and simulation of new layouts or robotic solutions before physical deployment. This ensures peak-period management, minimises costly downtime, facilitates quick integration of new robotic solutions, and enables seamless operations where different types of robots collaborate efficiently.

To achieve the necessary precision for this high-fidelity twin, Roboverse Reply utilised advanced scanner and camera technology mounted on Boston Dynamics’ mobile robot, Spot. The captured data is processed in a complex post-processing workflow and forms the basis for 3D models. Leveraging NVIDIA’s Omniverse simulation and AI infrastructure, including NVIDIA Isaac, NVIDIA’s AI and robotics development platform, a virtual control environment is being created to support accurate KPI computation and data-driven decision-making in complex scenarios, enabling the rapid simulation, training, and deployment of different types of robots.

Kai Uwe Ernst, Executive Partner at Reply, explained: “Creating a digital twin is more than just mapping a space – it’s about enabling intelligent orchestration at scale. By combining NVIDIA’s cutting-edge technologies with our expertise in AI and robotics, we’re laying the foundation for a new standard in robotic coordination. This system will allow different robotic fleets to communicate and collaborate seamlessly, unlocking new levels of efficiency and adaptability in logistics operations.”

The pilot project is launching at the Hermes Fulfilment logistics centre in Loehne (Germany) and will serve as a blueprint for additional Otto Group locations worldwide.

“More than three years ago we embarked on a journey to deploy AI and robotics in the field of logistics. Our experiences to date have shown the huge potential for improving efficiency and service,” commented Kay Schiebur, Member of the Executive Board, Services, Otto Group. “With NVIDIA and Reply, we are now ready to take intelligent automation to the next level. This partnership will provide the fundamental structure – a truly innovative way for our robots to communicate – allowing us to quickly scale up robotic solutions in our complex operations, strengthening our leadership in responsible business, especially here in Europe. We are always striving to improve our performance and ensure our future viability.”

This initiative with the Otto Group and NVIDIA underscores Roboverse Reply’s role as an implementation partner for AI-powered robotics and Physical AI in logistics. By developing the digital twin, Roboverse Reply is supporting the Otto Group in the step-by-step transformation of its logistics sites into a connected, virtual and highly scalable warehouse ecosystem. This shift ensures the Otto Group stays ahead of the competition through faster deliveries, lower operational costs, and unmatched flexibility.

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